Abstract: A plastic crush countermeasure for motor vehicles that includes a plastic insert and a reinforcement structure that provides impact and/or reinforcement characteristics and an attachment interface to the vehicle in a lighter weight structure. The crush countermeasure provides a lightweight crush system that provides comparable protection to current metal crush countermeasures using, in part, a plastic material. As such, the overall weight of a vehicle is reduced without any reduction in safety to passengers.

Abstract: A plastic crush countermeasure for motor vehicles that includes a plastic insert and a reinforcement structure that provides impact and/or reinforcement characteristics and an attachment interface to the vehicle in a lighter weight structure. The crush countermeasure provides a lightweight crush system that provides comparable protection to current metal crush countermeasures using, in part, a plastic material. As such, the overall weight of a vehicle is reduced without any reduction in safety to passengers.

Abstract: The present invention comprises a method of attaching plastic to a metal substrate and a part made by the method. A hydroformed metal section having top and bottom openings is provided. A plastic component is molded about the metal component and through the bottom opening. The plastic component includes a flange on one side thereof to secure the plastic component with the metal component.

Abstract: A thermally regulating heater and a heated seat made using these heaters wherein the resulting heated seat provides enhanced temperature control without the need of any temperature control system. The heaters include the use of a polymeric positive temperature coefficient composition that operates at lower trip temperatures than previous polymeric positive temperature coefficient compositions. The polymeric positive temperature coefficient composition have a trip temperature below the heat deflection temperature of the composition such that the polymeric positive temperature coefficient composition heats the heated seat to a temperature closer to the comfort level of an individual using the heated seat. Since the polymeric positive temperature coefficient composition uses plastic materials, the polymeric positive temperature coefficient composition can be formed into different shapes as needed using a molding process, such as injection molding.

Abstract: A front end module including a plastic component connected to a metallic substrate. The metallic substrate can be formed by hydroforming and shaped into a substantially unitary member. The plastic component is then molded about the metallic substrate and simultaneously forms connections thereto at discrete locations along the length of the metallic substrate.

Abstract: In an exemplary embodiment, an instrument panel assembly (10) includes an elongate beam structure (14) and a plurality of thermoplastic energy absorbers (16) coupled to the beam structure. The instrument panel assembly also includes at least one knee bolster (116) positioned adjacent the plurality of thermoplastic energy absorbers and an instrument panel (90).

Abstract: A front end module is described, wherein the module includes a plastic component connected to a metallic substrate. The metallic substrate can be formed by hydroforming and shaped into a substantially unitary member. The plastic component is then molded about the metallic substrate and simultaneously forms connections thereto at discrete locations along the length of the metallic substrate.

Abstract: The present invention comprises a method of attaching plastic to a metal substrate and a part made by the method. A hydroformed metal section having top and bottom openings is provided. A plastic component is molded about the metal component and through the bottom opening. The plastic component includes a flange on one side thereof to secure the plastic component with the metal component.

Abstract: In an exemplary embodiment, an instrument panel assembly (10) includes an elongate beam structure (14) and a plurality of thermoplastic energy absorbers (16) coupled to the beam structure. The instrument panel assembly also includes at least one knee bolster (116) positioned adjacent the plurality of thermoplastic energy absorbers and an instrument panel (90).